Device and method for manufacturing tobacco products

ABSTRACT

In general, the present invention is directed to the manufacture of tobacco products, and more specifically to a common device and method to manufacture cylindrical tobacco products such as cigarettes, cigars, and therapeutic medical products with varying diameters and geometries.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional PatentApplication Ser. No. 61/797,300 filed Dec. 04, 2012, which hereby isincorporated herein in its entirety by reference thereto.

This application also claims the benefit of U.S. Provisional PatentApplication Ser. No. 61/956,695 filed Jun. 14, 2013, which hereby isincorporated herein in its entirety by reference thereto.

FIELD OF THE INVENTION

In general, the present invention is directed to the manufacture oftobacco products, and more specifically to a common device and method tomanufacture cylindrical tobacco products such as cigarettes and cigarswith varying diameters.

BACKGROUND

Smoking articles, such as cigarettes, have a substantially cylindricalrod-shaped structure and include a charge, roll, or column of smokablematerial, such as shredded tobacco, surrounded by a paper wrapper, toform a “cigarette rod,” “smokable rod,” or a “tobacco rod.” A typicalcigarette has a cylindrical filter element axially aligned in anend-to-end relationship with the tobacco rod. Typically, the filterelement comprises plasticized cellulose acetate circumscribed by a papermaterial known as “plug wrap.” Certain cigarettes incorporate filterelements comprising, for example, activated charcoal particles.Typically, the filter element is attached to one end of the tobacco rodusing a circumscribing wrapping material known as “tipping paper.” Aventilated or air-diluted smoking article can be provided with anoptional air-dilution means, such as a series of perforations, each ofwhich extends through the tipping material and plug wrap. Conventionalautomated machines for making cigarette rods that have been employed forthe manufacture of commercially popular packaged cigarettes are of thetype commercially available from Molins PLC or Hauni-Werke Korber & Co.KG. For example, a description of a commercially available “Protos”cigarette-making machine is provided in U.S. Pat. No. 4,474,190 toBrand. Other types of equipment suitable for the manufacture ofcigarettes are set forth in U.S. Patent Application Publication No.2004/0129281 to Hancock et al. A cigarette-making machine for makingrelatively small amounts of cigarettes has been available commerciallyfrom Hauni-Werke Korber & Co. KG. Another type of portablecigarette-making machine has been set forth in U.S. Pat. No. 4,164,229to Hurt.

Cigarettes are commercially available in a wide variety of types. Forexample, different brands of cigarettes are available containingdifferent individual types of tobaccos having unique or characteristicflavors and aromas (e.g., Burley, Oriental, and Virginia tobaccos).Cigarettes are also available that contain blends of tobacco typesand/or flavoring agents in or on the tobacco. Different colors andflavors of wrappers and different types of filter elements are availableproviding variety in, for example, flavoring, strength of flavor, andtar yield. Conventionally, consumers obtain commercially availablecigarettes in a pack containing a single type of cigarette. Thus,consumers wishing to smoke different types of cigarettes typically haveto purchase multiple packs of cigarettes. Some consumers purchasewrapping materials, filters, and loose tobacco for so-called“hand-rolling” of their own cigarettes. While this approach allows aconsumer to produce a variety of his own cigarettes, the making processrequires a certain degree of skill, time, inconvenience, and/or somespecialized equipment. A variety of hand-operated devices formanufacturing individual cigarettes have been proposed. See, forexample, U.S. Pat. No. 2,376,103 to Wahl; U.S. Pat. No. 2,425,888 toMatteson et al.; U.S. Pat. No. 2,427,884 to Snodgrass; U.S. Pat. No.2,427,957 to Getts, Jr.; U.S. Pat. No. 2,496,375 to Carter; U.S. Pat.No. 2,594,747 to Du Laney; U.S. Pat. No. 2,699,788 to Kastner; U.S. Pat.No. 2,714,383 to Gee; U.S. Pat. No. 2,731,971 to Kastner; U.S. Pat. No.2,850,019 to Sosa; U.S. Pat. No. 2,868,209 to Marcotte; U.S. Pat. No.3,006,348 to Banning, Jr.; U.S. Pat. No.

3,011,498 to Armelin; U.S. Pat. No. 4,832,056 to Bryant et al.; U.S.Pat. No. 4,534,367 to Newsome; International Publication No. WO2004/110187 to Szabo; and European Publication No. 1177731 to BritishAmerican Tobacco (Germany) GmbH.

Various methods for filling paper cigarette tubes with tobacco have beenproposed. See, for example, U.S. Pat. No. 2,633,133 to Higgins; U.S.Pat. No. 3,124,141 to Seitter; U.S. Pat. No. 3,202,156 to Kappeler etal.; U.S. Pat. No. 3,892,245 to Asbill, Jr.; U.S. Pat. No. 4,167,948 toMoscovitch; U.S. Pat. No. 4,572,216 to Josuttis et al.; and U.S. Pat.No. 5,072,740 to Gatschmann et al. See also, U.S. Pat. No. 3,491,768 toPaynter and U.S. Pat. No. 3,693,313 to Sexstone which set forth mannersand methods for manufacturing individual cigarettes by filling a tube,or “spill,” with a tobacco charge and a filter plug. One type ofcigarette-making machine for the manufacture of one cigarette at a timeusing loose tobacco and a filtered cigarette tube has been marketed as“BUGLER™” filter cigarette-making machine by Brown &

Williamson Tobacco Corporation. Another type of automated machine forfilling pre-formed cigarette tubes with loose tobacco filler has beenavailable commercially as “Cig-a-mat” from Jenkins & Ott, Inc. A devicerepresentative of such a machine is described in U.S. Pat. No. 3,645,272to Jenkins et al. Yet another type of automated device for fillingpre-formed cigarette tubes with tobacco filler is anelectrically-operated cigarette-making machine that has been availablecommercially as “Easy Roller” from C. P. Rolling ApS of Denmark.

Another cigarette machine for filling pre-formed cigarette tubes withtobacco filler has been produced commercially by The Central TobaccoMfg. Co. Ltd. and marketed as “PREMIERE SUPERMATIC™” Other types ofcigarette machines for filling cigarette tubes with tobacco have beenmarketed as “Escort” and “Pressta Deluxe” by CTC Canada Inc. See, forexample, the representative types of machines set forth in U.S. Pat. No.3,127,900 and U.S. Pat. No. 4,771,793 both to Kastner.

U.S. Pat. No. 3,822,710 to Bramhill proposes manufacturing individualcigarettes by inserting a cartridge of tobacco into an empty filter-tipcigarette tube. Other manners and methods for manufacturing individualcigarettes are set forth in U.S. Pat. No. 4,887,617 to Ruppert et al.;U.S. Pat. No. 5,018,536 to Liebich; U.S. Pat. No. 5,105,830 to Brackmannet al.; U.S. Pat. No.

5,133,366 to Liebich; U.S. Pat. No. 5,141,000 to Ruppert et al.; U.S.Pat. No. 5,167,241 to Ruppert et al.; U.S. Pat. No. 5,197,495 to Ruppertet al.; U.S. Pat. No. 5,615,692 to Ruppert et al.; U.S. Pat. No.5,713,377 to Gerding et al.; and US Patent Publication No. 2006/0021625to Nyffeler.

Other methods for manufacturing small quantities of cigarettes, forexample 20 cigarettes, in an automated fashion by filling papercigarette tubes are disclosed in U.S. Pat. No. 7,597,105 to Barnes etal.; and US Publication No. 2007/0107738 to Barnes et al., each of whichhereby are incorporated herein in their entirety by reference thereto. Arepresentative device for manufacturing cigarettes disclosed in theseapplications can include a reservoir for containing loose tobaccofiller, a means for delivering a portion of the tobacco filler intopre-formed tubular wrappers, and a means for controlling the portion ofthe tobacco filler delivered into the wrappers, such as a compressionmechanism for arranging tobacco filler into a charge of tobacco fillerof pre-determined shape and size or a means for controlling the rate ofmovement of the wrappers as they are being filled. The device caninclude a tray or cartridge for containing a plurality of the tubularwrappers, which can be aligned with corresponding receptacles, and aninsertion means, such as plunger rods or auger conveyors, for deliveringeach charge of tobacco filler from a receptacle into a wrapper. Thecartridge, filled with manufactured cigarettes, can be removed from thecigarette-making device, excess tobacco can be cut away from the ends ofthe cigarettes with a cutting device, and the cigarettes can betransferred from the cartridge into a cigarette packaging device. Assuch, a small lot of cigarettes of consistent quality (for example, interms of components, dimensions, and weight) are produced. The devicecan be employed in a commercial setting such that a customer can choosea type or blend of tobacco filler for a package of cigarettes. For othermanners and methods of manufacturing small quantities of cigarettes, seeU.S. Pat. No. 7,565,818 to Thomas et al.

As shown above, there is a long and diverse history of prior art devotedto manufacturing tobacco products. However, a common theme among all ofthe prior art, is that the devices, whether automated or manual, aredesigned to manufacture a cylindrically shaped tobacco product of asimilar or fixed diameter.

Given this, there is a need for a manufacturing device and method toproduce cylindrically shaped tobacco products of varyingdiameters—thereby allowing the same device to manufacture bothrelatively “thin” cigarettes and “thicker” cigars.

SUMMARY OF THE INVENTION

In general, the present invention is directed to the manufacture oftobacco products, and more specifically to a common device and method tomanufacture cylindrical tobacco products such as cigarettes and cigarswith varying diameters.

One embodiment of the present invention describes a tobaccomanufacturing device comprising a rigid cylindrical shell open on oneend, a funneling device tapered to fit into the open end of thecylindrical shell, the lateral surface of cylindrical shell in verticalsegmented sections, the vertical segmented sections anchored on theclosed end of the cylindrical shell, and the vertical segmented sectionsseparable forming an opened cylinder.

Another embodiment of the present invention describes a tobaccomanufacturing device comprising a rigid cylindrical shell open on oneend, a funneling device tapered to fit into the open end of thecylindrical shell, and a tobacco grinder attachable to the saidfunneling device.

Another embodiment of the present invention describes a method formanufacturing a tobacco product comprising: first, inserting a thinliner into the open end of a cylindrical shell with a verticallysegmented lateral surface; second, inserting a funneling device into theopen end of the cylindrical shell; third, inserting tobacco into thefunneling device thereby filling the cylindrical shell; fourth,compressing the tobacco in the cylindrical shell; and fifth, removingthe compressed tobacco encased in the thin liner by expanding thevertically segmented cylindrical shell.

Another embodiment of the present invention describes a method formanufacturing a tobacco product comprising: first, inserting a thinliner into the open end of a cylindrical shell; second, inserting afunneling device into the open end of the cylindrical shell; third,inserting tobacco into the funneling device thereby filling thecylindrical shell; fourth, compressing the tobacco in the cylindricalshell; and fifth, removing the compressed tobacco encased in the thinliner.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention may be more completely understood in consideration of thefollowing detailed description of various embodiments of the inventionin connection with the accompanying drawings, in which:

FIG. 1 shows a schematic representation of one embodiment of the presentinvention depicting the funneling device inserted into the cylindricalshell.

FIG. 2 shows a schematic representation of the cylindrical shell.

FIG. 3 shows a schematic representation of the cylindrical shell withthe vertical segmented sections in the open configuration.

FIG. 4 shows a schematic representation of the funneling device depictedin FIG. 1.

While the invention is amenable to various modifications and alternativeforms, specifics thereof have been shown by way of example in thedrawings and will be described in detail. It should be understood,however, that the intention is not to limit the invention to theparticular embodiments described. On the contrary, the intention is tocover all modifications, equivalents, and alternatives falling withinthe spirit and scope of the invention as defined by the appended claims.

DETAILED DESCRIPTION

In general, the present invention is directed to the manufacture oftobacco products, and more specifically to a common device and method tomanufacture cylindrical tobacco products such as cigarettes and cigarswith varying diameters.

One embodiment of the present invention is depicted in FIG. 1 wherein amanual cigarette and/or cigar manufacturing device (hereafter“manufacturing device”) is shown schematically. The manufacturing deviceis comprised of a mechanical integrity element 14 which forms agenerally cylindrical surface 16. Prior to inserting tobacco, a thinsleeve of appropriate material may be inserted into the mechanicalintegrity element 14 which eventually will become the cylindricalsurface of the finished cigarette/cigar product.

Tobacco may be inserted into the thin sleeve encased within themechanical integrity element 14 by way of input funneling device 12,which may be inserted into the proximal end of the mechanical integrityelement 14. Ultimately, the thin sleeve is completely filled withtobacco material, which may be compressed by standard mechanical means.

The mechanical integrity element 14 may be comprised of a metal,hardened plastic, medical grade plastic, or similar plastic-likematerial. In addition, the mechanical integrity element 14 may have itslateral surface 16 segmented into discrete vertical elements which maybe mechanically separated (see FIGS. 2 and 3, elements 14 a thru 14 d).In practice, when tobacco has been sufficiently compressed, the discretevertical elements 14 a thru 14 d may be opened as shown in FIG. 3allowing for easy removal of the compressed cylindrical tobacco element.

In an alternative embodiment of the present invention, the mechanicalintegrity element 14 may be comprised of a cylindrical shell with arigid lateral surface 16 (i.e., not vertically segmented as described inthe embodiment above).

In one particular embodiment of the present invention ideally suited forthe manufacture of cigarettes, the mechanical integrity element 14 mayhave a rigid lateral surface 16 as described above with the followingphysical dimensions. The length and diameter of the rigid lateralsurface may be approximately 3 3/16 inch and 7/16 of an inchrespectively, consistent with the typical dimensions of cigarettestoday. In this embodiment of the invention, the funneling device shownin FIG. 4 may be tapered down to a diameter of ¼ of an inch for easyinsertion into the open end of the mechanical integrity element 14. Whenthis embodiment of the invention is employed for the manufacture ofcigarettes, an appropriate material for the thin liner (which eventuallywill become the cylindrical surface of the finished cigarette) may bechosen from the list of wood pulp, hemp paper, flax, rice straw, naturalcellulose, or any similar burnable material with the necessarymechanical integrity to support the encased compressed tobacco material.

In another particular embodiment of the present invention ideally suitedfor the manufacture of cigars, the mechanical integrity element 14 mayhave a rigid lateral surface 16 as described above with the followingphysical dimensions. The length and diameter of the rigid lateralsurface 16 may be approximately 4 9/16 inch and ¾ of an inchrespectively, consistent with the typical dimensions of cigars today. Inthis embodiment of the invention, the funneling device shown in FIG. 4may be tapered down to a diameter of ⅝ of an inch for easy insertioninto the open end of the mechanical integrity element 14. When thisembodiment of the invention is employed for the manufacture of cigars,an appropriate material for the thin liner (which eventually will becomethe cylindrical surface of the finished cigar) may be comprised oftobacco leaves or tobacco paper, or any similar burnable material withthe necessary mechanical integrity to support the encased compressedtobacco material.

In yet another particular embodiment of the present invention ideallysuited for the manufacture of therapeutic devices, such as medicalmarijuana or herbal remedies, the mechanical integrity element 14 mayhave a rigid lateral surface 16 as described above with the followingphysical dimensions. The length and diameter of the rigid lateralsurface 16 may be approximately 4 5/16 inch and 9/16 of an inchrespectively, consistent with the typical dimensions of medicalmarijuana products marketed today. In this embodiment of the invention,the funneling device shown in FIG. 4 may be tapered down to a diameterof 7/16 of an inch for easy insertion into the open end of themechanical integrity element 14. When this embodiment of the inventionis employed for the manufacture of therapeutic products, an appropriatematerial for the thin liner (which eventually will become thecylindrical surface of the finished therapeutic product) may be chosenfrom the list of wood pulp, hemp paper, flax, rice straw, naturalcellulose, or any similar burnable material with the necessarymechanical integrity to support the encased compressed therapeuticmaterial.

The procedure for manufacturing a tobacco product with a cylindricallyrigid (i.e., non-segmented) mechanical integrity element 14 follows asomewhat similar procedure—prior to inserting tobacco, a thin sleeve ofappropriate material may be inserted into the mechanical integrityelement 14 which eventually will become the cylindrical surface of thefinished cigarette/cigar/medical product.

Tobacco may be inserted into the thin sleeve encased within themechanical integrity element 14 by way of input funneling device 12,which may be inserted into the proximal end of the mechanical integrityelement 14. Ultimately, the thin sleeve is completely filled withtobacco material, which may be compressed by standard mechanical means.The thin liner may be manufactured from a material with a sufficientlysmooth surface and a diameter slightly smaller than the cylinder withinwhich it is encased, that the finished tobacco product may easily beextracted from the mechanical integrity element 14 by a variety of meansknown to those with skill in the art.

The present invention should not be considered limited to the particularexamples described above, but rather should be understood to cover allaspects of the invention as fairly set out in the attached claims.Various modifications, equivalent processes, as well as numerousstructures to which the present invention may be applicable will bereadily apparent to those of skill in the art to which the presentinvention is directed upon review of the present specification. Theclaims are intended to cover such modifications and devices.

I claim:
 1. A tobacco manufacturing device comprising; a rigidcylindrical shell open on one end; a funneling device tapered to fitinto the open end of the cylindrical shell; the lateral surface of saidcylindrical shell in vertically segmented sections; said verticallysegmented sections anchored on the closed end of the cylindrical shell;and said vertically segmented sections separable forming an openedcylinder.
 2. The device of claim 1 wherein a thin liner may be insertedinto the cylindrical shell prior to inserting the funneling device. 3.The device of claim 2 wherein tobacco may be inserted into the thinliner by way of the funneling device.
 4. The device of claim 1 whereinthe compacted tobacco encased in the thin liner may be easily removedfrom the cylinder with the vertically segmented sections in theseparated configuration.
 5. The device of claim 1 wherein the rigidcylindrical shell has a length of approximately 3 3/16 of an inch and adiameter of approximately 7/16 of an inch, and the funneling device istapered down to a diameter of approximately ¼ of an inch for insertioninto the open end of the cylindrical shell.
 6. The device of claim 1wherein the rigid cylindrical shell has a length of approximately 4 9/16of an inch and a diameter of approximately ¾ of an inch, and thefunneling device is tapered down to a diameter of approximately ⅝ of aninch for insertion into the open end of the cylindrical shell.
 7. Thedevice of claim 1 wherein the rigid cylindrical shell has a length ofapproximately 4 5/16 of an inch and a diameter of approximately 9/16 ofan inch, and the funneling device is tapered down to a diameterapproximately 7/16 of an inch for insertion into the open end of thecylindrical shell.
 8. A tobacco manufacturing device comprising; a rigidcylindrical shell open on one end; a funneling device tapered to fitinto the open end of the cylindrical shell; and a tobacco grinderattachable to the said funneling device,
 9. The device of claim 8wherein a thin liner may be inserted into the cylindrical shell prior toinserting the funneling device.
 10. The device of claim 8 wherein thetobacco grinder and funneling device may be in permanent mechanicalcommunication.
 11. The device of claim 8 wherein the rigid cylindricalshell has a length of approximately 3 3/16 of an inch and a diameter ofapproximately 7/16 of an inch, and the funneling device is tapered downto a diameter of approximately ¼ of an inch for insertion into the openend of the cylindrical shell.
 12. The device of claim 8 wherein therigid cylindrical shell has a length of approximately 4 9/16 of an inchand a diameter of approximately ¾ of an inch, and the funneling deviceis tapered down to a diameter of approximately ⅝ of an inch forinsertion into the open end of the cylindrical shell.
 13. The device ofclaim 8 wherein the rigid cylindrical shell has a length ofapproximately 4 5/16 of an inch and a diameter of approximately 9/16 ofan inch, and the funneling device is tapered down to a diameterapproximately 7/16 of an inch for insertion into the open end of thecylindrical shell.
 14. A method for manufacturing a tobacco productcomprising; first, inserting a thin liner into the open end of acylindrical shell with a vertically segmented lateral surface; second,inserting a funneling device into the open end of the said cylindricalshell; third, inserting tobacco into the funneling device therebyfilling the thin liner; fourth, compressing the tobacco in the thinliner; and fifth, removing the compressed tobacco encased in the thinliner by expanding the vertically segmented cylindrical shell.
 15. Amethod for manufacturing a tobacco product comprising; first, insertinga thin liner into the open end of a cylindrical shell; second, insertinga funneling device into the open end of the said cylindrical shell;third, inserting tobacco into the funneling device thereby filling thethin liner; fourth, compressing the tobacco in the thin liner; andfifth, removing the compressed tobacco encased in the thin liner.